My Volvo V40 - alterations

This part describes the steps I took to get the headlights installed in my Volvo V40.

Please note that this is the way I did it, and by no means the be-all-end-all of how-to's... Just trying to help someone out who might be interested in doing the same. I had quite a few questions after reading various posts on the Internet, and hope to bring some answers to others.

My V40 is a Model Year 1999 (production 10-1998), so it could be that there are some differences in the way it has to be done on your car.

I consulted the Haynes manual on this topic but found that in some parts it was way too detailed, and in others it skipped over non-obvious parts. Luckily my local Volvo dealer was nice enough to make me a print from VADIS ( image, dutch ) with the instructions how to remove the front bumper. The Haynes manual basically stated to remove the four bolts and pull... Luckily it was a little easier than that...

All bolts that need to be undone are M10 sized (apart from two phillips (crosshead) screws). Without a reversible ratchet drive the nuts on the back of the headlights are near impossible to get off or back on.

IMPORTANT: disconnect the negative lead from the battery before starting these steps, and make sure you know the radio code!

The first step is to unscrew the phillips screw that holds the turnsignal unit in place. The screw does not have to be taken out, just a few turns so the unit will come out.

Carefully take out the turn signal unit and make sure you don't break any parts off the back of the unit. Unclip the black connector from the back.

Next, remove the two nuts at the side of the headlight.

And remove the two nuts on the back of the headlight unit.
This sounds easier than it actually is. If your car has airconditioning installed, right behind the drivers side (LHD) headlight unit is part of the airco piping. As you can see on the photo, there is very little space and no straight way to access the nuts from the back. I used the ratchet drive with two extension parts (the smaller extension could go around corners) to undo the nuts. I used a magnet on a stick to keep the nut from falling inside the motor compartiment.

Unscrew the cover on the back of the headlight and disconnect the plugs by pulling the connectors off the back of the bulbs. Also disconnect the plug for the height adjustment motor.

The next step is to unscrew the big phillips screw in the wheel-well at the very end of the lower part of the bumper.

Next is the plug shown here.
Theoretically it is a plug that can be taken out easily by pulling out the center plug, but I ended up killing both and having to buy new ones (part number 30820141, about 80 cents a piece). I guess that plastic this old isn't flexible enough to withstand pulling it in the wrong places...

Next, remove three screws securing the bumper to the bottom cover.
Starting with the one directly underneath the plug in the previous step, remove the two others: one on the corner and one below the corner of the central air intake.

This should be enough to get the headlights out. The bumper is made of a flexible material, so you can pull the corner towards the front of the car (need to wiggle it a bit). Pull the bumper down enough to clear the way for the headlight to come out.
First pull the headlight towards you (at the grill-side) and when that side dislodges move the headlight to the center of the car to unhook the bolts at the side of the headlight.

(back to index)

	The first step is to unscrew the phillips screw that holds the turnsignal unit in place. The screw does not have to be taken out, just a few turns so the unit will come out.
	Carefully take out the turn signal unit and make sure you don't break any parts off the back of the unit. Unclip the black connector from the back.
	Next, remove the two nuts at the side of the headlight.
	And remove the two nuts on the back of the headlight unit. This sounds easier than it actually is. If your car has airconditioning installed, right behind the drivers side (LHD) headlight unit is part of the airco piping. As you can see on the photo, there is very little space and no straight way to access the nuts from the back. I used the ratchet drive with two extension parts (the smaller extension could go around corners) to undo the nuts. I used a magnet on a stick to keep the nut from falling inside the motor compartiment.
	Unscrew the cover on the back of the headlight and disconnect the plugs by pulling the connectors off the back of the bulbs. Also disconnect the plug for the height adjustment motor.
	The next step is to unscrew the big phillips screw in the wheel-well at the very end of the lower part of the bumper.
	Next is the plug shown here. Theoretically it is a plug that can be taken out easily by pulling out the center plug, but I ended up killing both and having to buy new ones (part number 30820141, about 80 cents a piece). I guess that plastic this old isn't flexible enough to withstand pulling it in the wrong places...
	Next, remove three screws securing the bumper to the bottom cover. Starting with the one directly underneath the plug in the previous step, remove the two others: one on the corner and one below the corner of the central air intake.
	This should be enough to get the headlights out. The bumper is made of a flexible material, so you can pull the corner towards the front of the car (need to wiggle it a bit). Pull the bumper down enough to clear the way for the headlight to come out. First pull the headlight towards you (at the grill-side) and when that side dislodges move the headlight to the center of the car to unhook the bolts at the side of the headlight.